FOAM SURFACE CLEANER

Abstract: The invention is a foam stabilizing composition which is used in conjunction with alkaline detergent products to produce a foam which is capable of clinging to vertical surfaces for extended time periods without breakdown or drying and ultimately rinse freely with water. The foam composition generally comprises an alkalinity source and a vinyl polymer. The invention also comprises a method of cleaning hard surfaces using the disclosed composition.

Description: FOAM SURFACE CLEANER Field of the Invention The invention generally relates to alkaline surface cleaning compositions. More specifically, the invention relates to compositions and methods for improving alkaline detergents by providing a stabilized foam capable of remaining on vertical and horizontal surfaces for extended time periods which also rinses freely with water. Background of the Invention Surface cleaning in any given environment is generally undertaken to maintain hygiene by removing residues left on the surface. Cleaning prevents contamination of substances, articles, and utensils as well as any other animate or inanimate objects such as food which may come in contact with the surface. While certain residues merely comprise carbonaceous debris, this debris may often provide a host or starting point for the growth of bacteria, microorganics, or other contaminants . Additionally, surfaces may also be cleaned to maintain their serviceability and mechanical integrity during operation. In any given industrial or commercial setting, surfaces such as walls, floors, countertops, as well as, ranges, grills, ovens, mixing tanks, storage racks, and the like may all present difficult surfaces to clean and disinfect. Such structures may all, from time to time, contain surfaces which retain large residual contamination which is difficult to clean. Further, given the extended use that such equipment is subjected to, repeated cleaning is an ongoing problem. However, the frequency of such cleaning generally requires a high level of efficiency with minimal expenditure of human resources in the form of time and manpower. For example, cleaners such as those useful in ovens often work by application to the intended surface for extended periods of time. Current industrial detergents designed to be foam applied are capable of producing large levels of foam. However, when applied to soiled or cleaned vertical surfaces, for example, the foam begins to sag, collapse, and move toward the floor within minutes of application. Soil removal is often incomplete due to the limited contact time of the foam. As a result, repeated applications of the cleaner is often necessary. Another problem associated with current foaming detergents is the drying of the foam on the surface prior to rinsing. Premature drying may also require another detergent application to solubilize the remaining detergent residues and, ultimately, produce a clean, streak-free surface. A number of cleaners have been developed for industrial and institutional surfaces. Gel compositions have been developed to clean and overcome the limited contact time between the detergent and soil associated with foam cleaning. These products utilize thickening agents to increase product to soil contact time in an attempt to improve soil removal. However, gel cleaners have some of the same limitations as foam cleaners including drying of the solution, poor rinseability, and poor visibility of the product once applied. Past attempts at cleaning compositions include Verboom, U.S. Patent No. 4,477,365, which discloses the use of a composition containing an alkaline metal hydroxide, betaine, alpha olefin sulfonate, and hydrotropic agent. Schoenholz, U.S. Patent 3,808,051 discloses a cleaning composition comprising an alkali metal salt of a weak organic acid, and a polyhidric alcohol which is used at a temperature of 250-550°F. Eisen, U.S. Patent 3,779,933 discloses a composition comprising an alkali metal hydroxide incorporating a nitrogen containing anionic surfactant, a thickening agent, and, optionally, a foam forming agent. Rink, U.S. Patent 4,135,947 discloses a water-based composition having a pH of less than 10 and comprising carbon dioxide neutralized amines, water soluble {solvents, and thickening agents. Heile, U.S. Patent 4,512,908 discloses an alkaline detergent composition comprising a chlorine source along with synthetic hectoright thickeners . Generally, these prior compositions teach the use of alkaline cleaning constituents in a gelled or foaming -state for use in applications such as ovens . However, to date, these compositions have not been able to overcome problems including a lack of ease in rinseability, requirements for repeated application, and overall efficacy. As a result, a need exists for a alkaline stabilized foam for hard surface cleaning which provides the overall stability and cleaning requirements which allow application to any number of given surfaces . Summary of the Invention In accordance with a first aspect of the invention, there is provided a method of stabilizing alkaline cleaning compositions using an adherent alkaline foam which when combined with an alkaline cleaning composition produces an adherent foam which provides cleaning efficacy, rinseability, and surface adherence, wherein the foam comprises an emulsified vinyl polymer effective in providing an adherent foam, and water. In accordance with an additional aspect of the invention, there is provided an adherent foam cleaner which comprises an adherent foam stabilizing additive of the invention combined with an alkaline cleaning agent such as a caustic cleaner, alkaline halogen cleaner, or .olvated halogen cleaner. In accordance with a further aspect of the Invention, there is provided a method of cleaning surfaces comprising the step of applying a foaming cleaning composition to the intended surface. In accordance with a further aspect of the invention, there is provided a cleaned surface resulting from use of the composition of the invention. The composition of the invention comprises an alkali stable emulsified vinyl polymer, optionally, a surfactant system along with various other adjuvants, and once combined with an alkaline cleaning agent a source of alkalinity. The composition displays physical properties such as rheology resulting in a long lasting foam having adhesion to non-horizontal surfaces. The long lasting foam permits the source of alkalinity in the cleaner to contact the soil for an extended period, and as a result, to promote the removal of soil. The foam is easily rinsed after sufficient time for removal of soil. The resulting foam composition allows application of the composition for extended periods of l;ime allowing for the significant cleaning of vertical surfaces . The invention may be used in conjunction with existing alkaline detergents to produce a foam which is capable of clinging to vertical and horizontal surfaces for extended time periods in excess of one hour without drying, and ultimately rinse freely with water. The invention overcomes the short comings of detergent systems by providing extended contact time (up to three hours on vertical surfaces), a highly visible stable foam, as well as providing a non-drying/free rinsing detergent. Detailed Description of the Preferred Embodiments The invention is a method of stabilizing alkaline cleaners using a viscous air entrained alkaline cleaning foam. The foam generally comprises a vinyl polymer or copolymer, as well as other optional adjuvants including surfactants, corrosion inhibitors, antimicrobial agents, builders, and the like. Once combined into a cleaning composition, the invention also comprises a foam stabilized cleaning composition as well as methods of using this composition and the cleaned surfaces resulting therefrom. The Polymeric Foam The adherent foam of the invention comprises an emulsified polymer or copolymer matrix. The polymer matrix generally forms a net-like fabric that, once neutralized, becomes a thickened complex or system. This thickened composition provides adherence to the foam of the invention as well as lowering the flow characteristics of the composition. As a result, the thickened foam is capable of adhering without flow, on non-horizontal surfaces. Further, the polymeric matrix assists in entraining air in the foam of the invention. This entrained air, in turn, assists in providing adhesive character to the claimed composition. Further, the entrained air also assists in the breakdown of the foam once removal is desired. In accordance with the invention, any number of vinyl compounds or monomers may be used to prepare the polymer or copolymer matrix used in the invention. Generally, vinyl polymers useful in the invention include polymers derived from vinyl acetals, vinyl acetates, vinyl alcohols, vinyl chlorides, vinyl ether monomers and polymers, n-vinyl monomers and polymers, vinyl fluorides, and the like. Especially useful are vinyl polymers prepared from acrylic acid and its derivatives. Acrylic acid (CH 2 = HC0 2 H) is a moderately strong carboxylic acid which is colorless liquid with an acrid odor. Generally acrylates are derivatives of both acrylic and rnethacrylic acid. Acrylic polymers and copolymers which may be used in the composition of the invention include alkyl acrylates such as methacrylate, ethylacrylate, propylacrylate, isopropylacrylate, and butylacrylate, sesquibutylacrylate, isobutylacrylate, tertbutylacrylate, hexylacrylate, heptylacrylate, 2- heptylacrylate, 2-ethylhexylacrylate, 2- ethylbutylacrylate, dodecylacrylate, hexadecylacrylate, 2-ethoxyethylacrylate, cyclohexylacrylate, and mixtures thereof. Other vinyl polymers which may be used include vinyl acyl ethyl polymers; n-vinyl amide polymers; styrene polymers including vinyl benzene polymers; vinyl butyryl polymers including vinyl acetyl polymers; vinyl carbazole polymers; vinyl ester polymers including vinyl acetate polymers, as well as other vinyl esters of normal saturated aliphatic acids including formic, propanoic, butyric, valeric, caproic, and the like; vinyl esters of aromatic acids including benzoic, chlorobenzoic, nitrobenzoic, cyanobenzoic, and naphthoic; as well as vinyl ether polymers. Hydrophilic monomers may also be utilized to produce the vinyl polymer in of the invention include acids and acid-esters of alpha, beta-unsaturated carboxylic acids such as methacrylic acid, acrylic acid, itaconic acid, aconitic acid, crotonic acid, mesaconic acid, carboxyethyl acrylic acid, maleic acid, fumaric acid and the like. Synthetic polymers resulting from polymerization of many of the preceding monomers which are useful as foaming agents in the invention include generally, polyvinyl alcohol (with varying degrees of hydrolysis), thylene/acrylic acid copolymers, ethylene/maleic anhydride copolymers, and styrene/maleic anhydride copolymers among others. Naturally derivatized and naturally occurring polymers such as casein compositions, natural gum compositions including karaya gum and guar gum, cellulosic and ether cellulosic compositions, starch, protein compositions, and starch-grafted copolymers are also useful as a foaming polymer of the present Invention. Those skilled in the art will realize that the preceding compounds and polymers are only exemplary of compounds and polymers which may be used as foam stabilizing agents in the composition of the present invention and this list should not be viewed as limiting. Preferably, the vinyl polymer comprises a polyacrylate/polymethacrylate copolymer Rohm & Haas as Accusol 820 or Alcogum -SL70 available from Alco chemical. The concentration of the foaming polymer used in the composition of the present invention will generally range from about 0.15 to 10 wt-%, preferably range from about 0.2 to 8 wt-%, and most preferably range from about 0.5 to 6 wt-% depending on the characteristics to be imparted to the resulting foam. The Surfactant System The composition of the invention may also comprise a surfactant system. The surfactant system bolsters the cleaning efficacy of the composition and functions as a penetrant to add wetability to the composition allowing easy dissolution and solubilization of the composition of the invention. Further, the surfactant system also facilitates solubilization of fatty soils and lowers surface tension, thus adding surface activity to the composition. Specifically, surfactants function to alter surface tension in the resulting compositions, provide sheeting, (aid in viscosity building) action, assist in soil removal and suspension by emulsifying soil and allowing removal through a subsequent flushing or rinse. Any number of surfactants may be used including organic surfactants such as anionic surfactants, zwitterionic or amphoteric surfactants, cationic surfactants and nonionic surfactants . Anionic surfactants are useful in removing oily soils. Anionic surfactants include alkyl carboxylates, such as sodium and potassium carboxylates, alkyl sulfates, alkyl ether sulfates, alkyl benzene sulfonates, alkyl sulfonates, sulfonated fatty acid esters and the like. Amphoteric or zwitterionic surfactants are also useful in providing detergency, emulsification, wetting and conditioning properties. Representative amphoteric surfactants include N-coco-3-aminopropionic acid and acid salts, N-tallow-3-iminodiproprionate salts. As well as N-lauryl-3-iminodiproprionate disodium salt, N- carboxymethyl-N-cocoalkyl-N-dimethylammonium hydroxide, N-carboxymethyl-N-dimethyl-N-(9-octadecenyl)ammonium hydroxide, (1-carboxyheptadecyl)trimethylammonium hydroxide, ( 1-carboxyundecyl)trimethylammonium hydroxide, N-cocoamidoethyl-N-hydroxyethylglycine sodium salt, N-hydroxyethyl-N-stearaminoglycine sodium salt, N- hydroxyethyl-N-lauramido-β-alanine sodium salt, N- cocoamino-N-hydroxyethyl-β-alanine sodium salt, as well as mixed alicyclic amines, and their ethoxylated and sulfated sodium salts, 2-alkyl-l-carboxymethyl-l- hydroxyethyl-2-imidazolinium hydroxide sodium salt or free acid wherein the alkyl group may be nonyl, undecyl, or heptadecyl. Also useful are 1, 1-bis(carboxymethyl)- 2-undecyl-2-imidazolinium hydroxide disodium salt and oleic acid-ethylenediamine condensate, propoxylated and sulfated sodium salt. Amine oxide amphoteric surfactants are also useful. This list is by no means exclusive or limiting. Cationic surfactants may also be used including quaternary ammonium compounds such as N-alkyl(C 12 _ι 8 ) dimethylbenzyl ammonium chloride, N- tetradecyldimethylbenzyl ammonium chloride monohydrate, N-alkyl(C 12 _ IA ) dimethyl 1-napthylmethyl ammonium chloride available commercially from manufacturers such as Stepan Chemical Company. Preferably, when present, the surfactants used in the invention comprise one or more nonionic surfactants . Nonionic surfactants which are useful in the invention include polyoxyalkylene nonionic detergents such as C 8 . 22 normal fatty alcohol-ethylene oxides or propylene oxide condensates, (that is the condensation products of one mole of fatty alcohol containing 8-22 carbon atoms with from 2 to 20 moles of ethylene oxide or propylene oxide); polyoxypropylene-polyoxyethylene condensates having the formula HO(C^O) x (C 3 H 6 0) y H wherein (C 2 H 4 0) x equals at least 15% of the polymer and (C 3 H 6 0) y equals 20-90% of the total weight of the compound; alkylpolyoxypropylene-polyoxyethylene condensates having the formula R0-(C 3 H 6 0) x (C 2 H /) 0) y H where R is a C^^ alkyl group and x and y each represent an integer of from 2 to 98; polyoxyalkylene glycols; butyleneoxide capped alcohol ethoxylate having the formula R(OC 2 H 4 ) y (OC^Hg) X 0H where R is a C 8 . 18 alkyl group and y is from about 3.5 to L0 and x is an integer from about 0.5 to 1.5; benzyl ethers of polyoxyethylene and condensates of alkyl phenols having the formula R(C 6 H A ) (OC 2 H ) x OCH 2 C 6 H 5 wherein R is a C 6 . 20 alkyl group and x is an integer of from 5 to 40; and alkyl phenoxy polyoxyethylene ethanols having the formula R(C 6 H (OC 2 H 4 ) x OH wherein R is a C 8 . 20 alkyl group and x is an integer from 3 to 20. Preferably, nonionics such as nonyl phenol ethoxylates, and linear alcohol ethoxylates may be used in the invention. The surfactants may be used at concentrations ranging from about 0.00005 wt-% to 1 wt- %, preferably about 0.0001 wt-% to 1 wt-%, most preferably about 0.0002 wt-% to 0.5 wt-%. Adjuvants The foam composition of the invention may also comprises any number of other adjuvants, such as alkalinity sources corrosion inhibitors, sanitizers, builders, and the like. Corrosion inhibitors may be used to prevent the composition of the invention from facilitating corrosion of the surface to which it is applied. Exemplary corrosion inhibitors include silicates such as sodium inetasilicate, and potassium metasilicate as well as thiazoles such as benzotriazole, tolytriazole, and mercapto benzothiazol. Generally, the concentration of the corrosion inhibitor will range from about 0.01 to 5 wt-%, preferably from about 0.1 to 3 wt-%, and most preferably from about .5 to 2 wt-%. In order to prevent the formation of precipitates or other salts, the foam cleaning composition of the present invention may generally comprise builders, and chelating agents or sequestrants such as phosphates, phosphonates, acrylic polymers, and compounds such as EDTA or derivatives thereof. Generally, sequestrants are those molecules capable of coordinating the metal ions commonly found in service water and thereby preventing the metal ions from interfering with the functioning of detersive components with the composition. The number of covalent bonds capable of being formed by a sequestrant upon a single hardness ion is reflected by labeling the sequestrant as bidentate (2), tridentate (3), tetradentate (4), etc. Any number of sequestrants may be used in accordance with the invention. Representative sequestrants include salts of amino carboxylic acids, phosphonic acid salts, water soluble acrylic polymers, among others. Suitable amino carboxylic acid chelating agents include n-hydroxyethyliminodiacetic acid, nitrilotriacetic acid (NTA) , ethylenediaminetetraacetic acid (EDTA) , hydroxyethyl-ethylenediaminetriacetic acid (HEDTA), and diethylenetriaminepentaacetic acid (DTPA) . When used, these amino carboxylic acids are generally present in concentrations ranging from about 1 wt-% to 25 wt-%, preferably from about 5 wt-% to 20 wt-%, and most preferably from about 10 wt-% to 15 wt-%. Other suitable sequestrants include water soluble acrylic polymer to condition the wash solutions under end use conditions. Such polymers include polyacrylic acid, polymethacrylic acid, acrylic acid-methacrylic acid copolymer, hydrolyzed polyacrylamide, hydrolyzed methacrylamide, hydrolyzed acrylamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrile rnethacrylonitrile copolymers, or mixtures thereof. Water soluble salts or partial salts of these polymers such as these respective alkali metal (for example, sodium or potassium) or ammonium salts can also be used. The weight average molecular weight of the polymers is from about 4000 to about 12000. Preferred polymers include polyacrylic acid, the partial sodium salts of polyacrylic acid or sodium polyacrylate having an average molecular weight within the range of 4000 to 8000. These acrylic polymers are generally useful in concentrations ranging from about 0.5 wt-% to 20 wt-%, preferably from about 1 wt-% to 10 wt-%, and most preferably from about 1 wt-% to 5 wt-%. Also useful as sequestrants are phosphonic acids and phosphonic acid salts. In addition to conditioning the water, organic phosphonic acids and phosphonic acid salts provide a grease dispersing character. Such useful phosphonic acids include, mono, di, tri and tetra-phosphonic acids which can also contain groups capable of forming anions under alkaline conditions such as carboxy, hydroxy, thio and the like. Among these are phosphonic acids having the formula R 1 N[C 2 P0 3 H 2 ] 2 or R 2 C(P0 3 H 2 ) 2 OH wherein R may be a -[(lower) alkylene]N[CH 2 P0 3 H 2 ] 2 or a third (CH 2 P0 3 H 2 ) moiety; and wherein R 2 is selected from the group consisting of ^C alkyl. The phosphonic acid may also comprise a low molecular weight phosphonopolycarboxylic acid such as one having about 2-4 carboxylic acid moieties and about 1-3 phosphonic acid groups. Such acids include 1- phosphono-1-methylsuccinc acid, phosphonosuccinic acid and 2-phosphonoubtane-l,2,4-tricarboxylic acid. When used as a sequestrant in the invention, phosphonic acids or salts are present in a concentration ranging from about 0.25 wt-% to 15 wt-%, preferably from about 1 wt-% to 10 wt-%, and most preferably from about L wt-% to 5 wt-% . Any number of chemical agents having microbial efficacy may be used in the invention. Representative compositions which could be used as antimicrobial agents in the invention include commonly available aldehydes such as formaldehyde and glutaraldehyde; iodophors such as iodine-nonionic surfactant complexes, iodine- polyvinyl pyrrolidone complexes, iodine-quaternary ammonium chloride complexes and amphoteric iodine-amine oxide complexes and the like; organic chlorine releasing agents such as cyanurates, cyanuric acids, and dichlorocyanuric dihydrates which are commercially available from FMC and Monsanto as their CDB and ACL product lines, respectively; fatty acids such as decanoic acid and the like; anionic surfactants such as dodecylbenzene sulfonic acid and sodium 1-octane sulfonate; phenols such as o-phenylphenol, 2,4,5- trichlorophenol, and 2,3,4,6-tetrachlorophenol commercially available from sources such as Dow Chemical Company and Mobay Chemical Company. Also useful as antimicrobials in the invention are cationic surfactants including quaternary ammonium chloride surfactants such as N-alkyl(C 12 -.ι 8 ) dimethylbenzyl ammonium chloride, N-alkyl(C . 18 ) dimethylbenzyl ammonium chloride, N- tetradecyldimethylbenzyl ammonium chloride monohydrate, N-alkyl(C 12 . ) dimethyl 1-napthylmethyl ammonium chloride available commercially from manufacturers such as Stepan Chemical Company. When present, an antimicrobial agent must have a concentration effectively necessary for the required action to be provided. Generally, the concentration of antimicrobial agent may range from about .005 to 0.2 wt- %, preferably from about 0.005 to 0.15 wt-%, and most preferably from about 0.01 to 0.1 wt-%. Preferably, the antimicrobial agent comprise a mixture of sorbic acid and benzoic in the foam stabilizing composition at a concentration of about 0.05 wt-% and 0.15 wt-%, respectively. FOAM FORMULATION In preparation, the vinyl polymer emulsion may be combined with a source of alkalinity such as a hydroxide salt, carbonate, phosphate, amine or mixture thereof. The purpose of the alkalinity source is to neutralize the often acidic character of the vinyl polymer and reduce the amount of alkalinity scavenged from the alkaline cleaner with which the foam will later be combined. The foam may be neutralized with any number of alkalinity sources, including those disclosed below, to attain a pH of about 4 to 6, preferably about 4 to 5.5, and most preferably about 4.5 to 5.5. Once neutralized a preservative system may be introduced into the composition along with any other adjuvants desired for use in the foam or cleaner. A summary of concentrations for the foam is provided below in Table 1. TABLE 1 (Wt-% as a percentage of foam composition) useful workinq preferred Vinyl Polymer 8-30 10-25 12-22 Surfactant 0.1-5 0.15-3 0.25-2 Alkalinity (pH) 4-6 4-5.5 4.5-5.5 Antimicrobial 0.025-0 .5 0.05-0.4 0.1-0.3 Water q.s q.s. q.s. Cleaninq Compositions The foam stabilizing additive may be used in combination with any number of cleaning compositions such as alkaline or caustic cleaners, halogenated alkaline cleaners, and solvated alkaline cleaners among others . Alkaline or caustic cleaners may be based upon any number of alkali or alkaline earth metal hydroxides, such as for example sodium hydroxide (caustic). In order to achieve an alkaline pH, the cleaning composition generally requires an alkalinity source. This higher pH increases the efficacy of soil removal and sediment breakdown when the chemical is placed in use and further facilitates the rapid dispersion of soils . The source of alkalinity also functions to raise the pH of the form of the invention. The effect of this pH increase is to thicken the composition from a water thin complex to a foam capable of entraining air and adhering to horizontal and vertical surfaces. The general character of the alkalinity source is limited only to those chemical compositions which have a greater solubility. That is, the alkalinity source should not contribute metal ions which promote the formation of precipitates or film salts. Exemplary alkalinity sources include silicates, hydroxides, phosphates, amines, and carbonates. Amines useful in accord with this invention include monoethanol, diethanol, and triethanol amines. Generally, when an amine compound is used or the alkalinity source, the concentration of the amine may range from about 0.10 wt-% to 5 wt-%, preferably from about 0.10 wt-% to 4.5 wt-%, and most preferably from about 0.25 wt-% to 3 wt-%. Silicates useful in accord with this invention include alkaline metal ortho, meta-, di-, tri-, and tetrasilicates such as sodium orthosilicate, sodium sesquisilicate, sodium sesquisilicate pentahydrate, sodium metasilicate, sodium metasilicate pentahydrate, sodium metasilicate hexahydrate, sodium metasilicate octahydrate, sodium metasilicate nanohydrate, sodium disilicate, sodium trisilicate, sodium tetrasilicate, potassium metasilicate, potassium metasilicate hemihydrate, potassium silicate monohydrate, potassium disilicate, potassium disilicate monohydrate, potassium tetrasilicate, potassium, tetrasilicate monohydrate, or ixtures thereof. Generally, when a silicate compound is used as the alkalinity source in the invention, the concentration of the silicate will range from about 0.5 wt-% to 8 wt-%, preferably from about 0.5 wt-% to 5 wt-%, and most preferably from about 0.5 wt-% to 3 wt-%. Alkali metal hydroxides have also been found useful as an alkalinity source in the invention. Alkali metal hydroxides are generally exemplified by species such as potassium, sodium, and lithium hydroxide salts as well as other alkali hydroxide salts. Mixtures of these species may also be used. When present, the alkaline hydroxide concentration generally ranges from about 0.25 wt-% to 10 wt-%, preferably from about 0.5 wt-% to 8 wt- %, and most preferably from about 1 wt-% to 5 wt-%. An additional source of alkalinity includes carbonates . Alkali metal carbonates which may be used in the invention include sodium carbonate, potassium carbonate, sodium or potassium bicarbonate, or εesquicarbonate, among others. Preferred carbonates include sodium and potassium carbonates. When carbonates are used, the concentration of these agents generally ranges from about 0.5 wt-% to 12 wt-%, preferably from about 1 wt-% to 10 wt-%, and most preferably from about 1.5 wt-% to 8.5 wt-%. Phosphates which may be used as an alkalinity source in accordance with the invention include cyclic phosphates such as sodium or potassium orthophosphate, alkaline condensed phosphates such as sodium or potassium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, and the like. In using phosphates, the concentration will generally range from about 1 wt-% to 20 wt-%, preferably from about 1 wt-% to 10 wt-%, and most preferably from about 2 wt-% to 8 wt-%. Combinations of these alkalinity sources may also be used. The pH of the composition, in use solution, ranges from about 6.5 to 14, preferably from about 7 to 14, and most preferably from about 7.5 to 14. TABLE 2 (Wt-% as a percentage of total cleaning composition) Constituent Useful Working Preferred ALkalinity Source Hydroxide Salts 0.25-10 0.5-8 1-5 SLlicates 0.5-8 0.5-5 0.5-3 Carbonates 0.5-12 1-10 1.5-8.5 Phosphates 1-20 1-10 2-8 Amines 0.10-5.0 0.10-4.5 0.25-3.0 TABLE 2 (Cont.) (Wt-% as a percentage of total cleaning composition) Constituent Useful Workinq Preferred Vinyl Polymer 0.15-10 0.2-8 0.5-6 Emulsion Surfactant 0.00005-1.0 0.0001-1.0 0.0002-0.5 Antimicrobial 0.005-0.2 0.005-0.15 0.01-0.1 Halogenated alkaline cleaners may comprise any number of alkalinity sources such as those useful with the adherent foam of the invention. In addition to p.roviding cleaning efficacy, halogens may be used to disinfect, sanitize or otherwise enhance the antimicrobial character of the surface of application. Additionally, a halogen source may also be present such as chlorine, bromine, iodine, or fluorine among others. Another cleaning composition with which the foam of the invention may be used is solvated (organic) cleaners having an organic character. Generally, organic solvents function to dissolve, suspend, or otherwise charge the physical properties of materials intended to be removed by the cleaners. Exemplary families of organic solvents include amines, olephinic compounds, short chain and long chain carboxylic acids, and alcohols including mono-, di-, and tri- functional aLcohols among other compounds. Again any of the aLkalinity sources mentioned earlier may be used with the invention. Organic cosolvents preferred for use in these compositions include mono-, di-, and polyfunctional alcohols. A summary of the concentrations, of cleaning compositions may be found in Table 3. TABLE 3 (Wt-% as a percentage of total cleaning composition) useful working preferred foam stabilizing additive 1.0-10.0 1.50-9.0 2.0-8.0 cleaning composition 0.05-20.0 0.05-18.0 0.1-15.0 water q.s. q.s. q.s. The formulated composition may be applied through any number of means known to those of skill in the art such as single and multiple container foam applicators like Klenzade Model and 2S Foa ers available from Ecolab Inc. Workinq Examples The invention will be further described by reference to the following detailed examples. Foam Stabilizing Composition A foam stabilizing composition was formulated having the following constituents and concentration. FORMULA 1 Raw Material Wt% Distilled water 49.50 NaOH (50% w/v) 0.20 Sorbic acid 0.05 Benzoic acid 0.15 Hidacid Pyranine dye, (CI #59040) 0.10 Acrylic Copolymer emulsion* 50.0 *(Acusol 820-Rohm and Haas Co, or Gum SL-70 Alco Chemical Co. ) Various detergent compositions were then formulated as seen by Detergent Compositions A through E. Detergent Composition A Percent (Wt- • l Raw Material 32.30 Soft Water 0.10 EDTA 31.20 Sodium Hydroxide 50% (w/v) 6.40 Organic chelant 30.00 Sodium Hypochlorite Detergent Composition B Percent (Wt-%) Raw Material 89.20 Sodium Hydroxide (50% w/v) 4.35 Soft Water 0.75 Nonionic Surfactant 0.10 Organic Chelant 5.60 40% Sodium Gluconate Detergent Composition C Percent (Wt-%) Raw Material 51.70 Deionized Water 1.40 Organic Chelant 40.00 Sodium hydroxide 50% 1.00 Nonionic surfactant 2.00 Amine Oxide 4.00 Amphoteric surfactant Detergent Composition D Percent (Wt-%) Raw Material 69.9 Soft Water 1 Versene 100 (EDTA) 7.5 TKPP, 60% (w/v) 1.6 NaOH, 50% (w/v) 1 Sodium Metasilicate, Anhy. 3 Anionic Surfactant 5 Nonionic Surfactant 3 Phosphate Ester 8 Glycol Ether Detergent Composition E Raw Material t % 50% NaOH 96, .45 50% Gluconic acid 2,.50 Soft Water 1,.00 Nonionic Surfactant 0,.05 The foam stabilizing composition was then combined with the various Detergent Compositions (A through E) and tested. Workinq Example 1 Foam stabilizing Composition with Detergent Composition A. In a fifteen gallon foam application pressure vessel, 1,136 grams of Formula 1 was mixed with 17,059 grams of Soft Water. To this mixture was added, while stirring, 730.0 grams of detergent composition A containing over 10% NaOH and over 3% sodium hypochlorite. The vessel was pressurized to 63 p.s.i. and the air-liquid controls adjusted to 1/4 turn open air - 1 and 1/2 turns open liquid. The resulting air- solution combination was applied to vertical stainless steel walls as a rich foam with a finished thickness of 0.5 - 0.25 inches. This foam did not flow off the wall, but instead remained as applied without collapse for ten minutes. After forty minutes the foam still provided 100% coverage of the area to which it was applied with only slight collapse. At this time, the foam was rinsed off with cold water at low pressure and the Foam was found to rinse off easily and completely. Working Example 2 Foam stabilizing composition with Detergent Composition B. In a fifteen gallon foam application pressure vessel 1,510 grams of Formula 1 was combined with 15,900 grams soft water. To this mixture was added, while stirring 1,510 grams of Detergent Composition B with over 40% NaOH, a nonionic surfactant and chelating agents. The vessel was pressurized to 63 p.s.i. with air and the air-liquid controls adjusted to 1 and 1/2 turns open liquid and 1/4 turn open air. The resulting air-solution combination was applied to vertical stainless steel walls as a dry foam with a finished thickness of 1.0 - 1.5 inches. This foam did not flow off the wall, but instead remained as applied without collapse for ten minutes with 100% coverage of the wall at this time. At 15 minutes after application the areas with a 1.5" thick foam coating had sagged slightly but the wall remained 100% covered by the foam. At 20 minutes after application the foam had sagged sufficiently to clear 10% of the stainless steel wall of foam but the remainder of the wall was still coated. This foam was rinsed off with low pressure cold water and the foam was found to rinse easily and completely at this time. Working Example 3 Foam stabilizing composition with Detergent Composition C. With a dual intake wall mounted foam unit (Model K low pressure/standard pressure produced by Ecolab Incorporated) the combination of Formula 1 with a highly alkaline self foaming detergent with a blend of amphoteric surfactants and a level of NaOH in excess of 15% was tested for dynamic mixing and production of the stable alkaline foam. The unit operated by allowing a flow of water through a venturi to aspirate concentrated products into the stream of water and subsequent to their mixing injects air under pressure into the fluid stream. With a concentration of Formula 1 equivalent to 7.5% and 1.6% of the Detergent Composition C determined by flow rate of the water and draw rate of the concentrates, the unit Model K LP/SP produced a very thick clinging foam on vertical stainless steel walls which did not flow off the walls upon application. After 75 minutes the foam was found to be still 80% as foam with 20% collapsed but 100% coverage of the application area. The foam was easily rinsed off with low pressure hot water rinse (130 degrees F) . Working Example 4 Foam stabilizing composition with Detergent Composition D. In a fifteen gallon foam application pressure vessel 570 grams of Formula 1 was mixed with 17,700 grams of soft water. To this mixture was added, with stirring, 630 grams of Detergent Composition D with a water soluble solvent, anionic and nonionic surfactants. The vessel was pressurized to 62 p.s.i. and the air- liquid controls adjusted to 1 and 1/2 turns open liquid, 1/8 turn open air. The resulting air-liquid combination was applied to stainless steel walls as a very wet foam which did not flow off the wall but instead flowed to an even foam coating of 1/8 inch thick. At 10 minutes a ter foam application there was no change in foam appearance with 100% coverage of stainless steel wall surface. At thirty minutes after foam application, a slight thinning of foam thickness was visible but the stainless steel wall surface was still coated 100% by the foam. Foam rinsed with low pressure cold water at this time. The foam was easily rinsed off. Working Example 5 Foam stabilizing composition with Detergent Composition E. In a fifteen gallon foam application pressure vessel 1,140 grams of Formula 1 was mixed with 15,830 grams soft water. To this mixture was added, while stirring, 1,960 grams of a Detergent Composition E with NaOH content in excess of 45% NaOH. The vessel was pressurized to 63 p.s.i. and the air-liquid controls adjusted to 1/4 turn open air and 2 turns open liquid. The resulting air-solution combination was applied to vertical stainless steel walls with a finished thickness of 1-2 inches. At 15 minutes after application there was 100% coverage with no change in foam appearance. At 25 minutes after application of the foam 95% of the area was covered with the remaining foam having slid to the floor. The foam rinsed easily with cold water low pressure rinse. Comparative Example 1 In a fifteen gallon foam application pressure vessel 1,890 grams of a detergent composition C was combined with 17,030 grams of soft water, the solution was stirred to mix. The vessel was pressurized to 63 p.s.i. with air and the air-liquid controls adjusted to 1 and 1/2 turns open liquid and 1/8 turn open air. The resulting air-solution combination was applied to vertical stainless steel walls. The foam produced was thick and wet and immediately upon application began to fLow downward. At 10 minutes after application of the foam to the wall 95% of the wall was clear of any foam coating and the remaining area had a thin coating of foam. At fifteen minutes the 5% of the wall which had a thin foam coating at 10 minutes was coated with film without foam characteristics. The above discussion, examples and data illustrate our current understanding of the invention. However, since many variations of the invention can be made without departing from the spirit and scope of the invention, the invention resides wholly in the claims hereinafter appended.

Claims: WE CLAIM AS OUR INVENTION: 1. A method of stabilizing alkaline cleaning compositions using an adherent foam composition said Eoam composition comprising an alkalinity source, a vinyl polymer emulsion to provide an adherent foam, and a balance of water, said method comprising the step of adding said foam composition to said alkaline cleaner. 2. The method of claim 1 wherein said alkalinity source comprise an alkali or alkaline earth hydroxide. 3. The method of claim 1 wherein said alkalinity source is selected from the group consisting of a silicate, a hydroxide, a phosphate, a carbonate, an amine, and mixtures thereof. 4. The method of claim 1 wherein said alkalinity source is present in a concentration ranging from about 0.10 wt-% to 12 wt-%. 5. The method of claim 1 wherein after formulation said foam cleaning composition has a pH of about 6.5 or greater. 6. The method of claim 1 wherein said vinyl polymer emulsion comprise one or more acrylic monomers. 7. The method of claim 1 wherein said vinyl polymer emulsion comprises one or more monomers selected from the group consisting of a vinyl acetal monomer, a vinyl acetate monomer, a vinyl alcohol monomer, a vinyl chloride monomer, a vinyl ether monomer, an n-vinyl monomer, a vinyl fluoride monomer, and mixtures thereof. 8. The method of claim 6 wherein said acrylic monomers are selected from the group consisting of acrylate, methylacrylate, ethylacrylate, propyl acrylate, isopropylacrylate, butylacrylate, sesquibutylacrylate, isobutylacrylate, tertbutylacrylate, hexylacrylate, heptylacrylate, 2- heptylacrylate, 2-ethylhexylacrylate, 2- ethylbutylacrylate, dodecylacrylate, hexadecylacrylate, 2-ethoxyethyl acrylate, and mixtures thereof. 9. The method of claim 1 wherein said vinyl polymer comprises an ester of an alpha, beta-unsaturated carboxylic acid. 10. The method of claim 9 wherein said alpha, beta unsaturated carboxylic acid ester is selected from the group consisting of a methacrylic acid ester, an acrylic acid ester, an itaconic acid ester, an aconitic acid ester, a crotonic acid ester, a mesaconic acid ester, a carboxyethyl acrylic acid ester, a maleic acid ester, a fumaric acid ester, and mixtures thereof. 11. The method of claim 1 wherein said vinyl polymer emulsion is present in a concentration ranging from about 0.15 wt-% to 10 wt-%. 12. The method of claim 1 wherein said foam composition comprises a surfactant. 13. The method of claim 12 wherein said surfactant is selected from the group an anionic surfactant, a cationic surfactant, an amphoteric surfactant, a nonionic surfactant, and mixtures thereof. 14. The method of claim 12 wherein said surfactant is present in a concentration ranging from about 0.00005 wt-% to 1.0 wt-%. 15. The method of claim 13 wherein said surfactant comprises a nonionic surfactant present in a concentration ranging from about 0.00005 wt-% to 1.0 wt- %. 16. A method of stabilizing alkaline cleaning compositions using an adherent foam composition, said foam composition comprising from about 0.01 wt-% to 0.5 wt-% of an alkalinity source from about 12.0 wt-% to 22 wt-% of a vinyl acrylic polymer from about 0.25 wt-% to 2 wt-% of a nonionic surfactant and a balance of water, wherein the pH of the composition is at about pH 4.5, said method comprising the step of adding said adherent foam to an alkaline cleaning composition. 17. The method of claim 16 wherein said alkalinity source comprise an alkali or alkaline earth metal hydroxide. 18. The method of claim 16 wherein said alkalinity source is selected from the group consisting of a hydroxide, a phosphate, a carbonate, an amine, and mixtures thereof. 19. The method of claim 16 wherein after formulation said foam cleaning composition has a pH of about 6.5 or greater. 20. The method of claim 16 wherein said vinyl acrylic polymer comprises one or more acrylic monomers selected from the group consisting of methylacrylate, ethylacrylate, propyl acrylate, isopropylacrylate, butylacrylate, sesquibutylacrylate, isobutylacrylate, tertbutylacrylate, hexylacrylate, heptylacrylate, 2- heptylacrylate, 2-ethylhexylacrylate, 2- ethylbutylacrylate, dodecylacrylate, hexadecylacrylate, 2-ethoxyethyl acrylate, and mixtures thereof. 21. The method of claim 16 wherein said vinyl acrylic polymer comprises an ester of an alpha, beta- unsaturated carboxylic acid. 22. The method of claim 21 wherein said alpha, beta unsaturated carboxylic acid ester is selected from the group consisting of a methacrylic acid ester, an acrylic acid ester, an itaconic acid ester, an aconitic acid ester, a crotonic acid ester, a esaconic acid ester, a carboxyethyl acrylic acid ester, a maleic acid ester, a fumaric acid ester, and mixtures thereof. 23. The method of claim 16 wherein said composition additionally comprises a surfactant selected from the group an anionic surfactant, a cationic surfactant, an amphoteric surfactant, a nonionic surfactant, and mixtures thereof. 24. An adherent foam cleaning composition comprising: (a) an amount of alkaline cleaner effective in removal of soil; and (b) an adherent alkaline foam composition comprising: (i) an amount of alkalinity source effective to raise the pH of said foam cleaning composition to about pH 6.5 or greater; (ii) an amount of vinyl polymer emulsion effective in providing an adherent foam; and (c) a balance of water. 25. The composition of claim 24 wherein said alkaline cleaner is selected from the group consisting of an alkaline solvated detergent, an alkaline halogenated detergent, an alkaline detergent, and mixtures thereof. 26. The composition of claim 24 wherein said composition comprises from about 0.50 to 20.0 wt-% of alkaline cleaner. 27. The composition of claim 24 comprising from about 0.15 wt-% to 10.0 wt-% adherent foam. 28. The composition of claim 27 wherein said adherent alkaline foam alkalinity source comprise an alkali or alkaline earth hydroxide. 29. The composition of claim 24 wherein said adherent alkaline foam alkalinity source is selected from the group consisting of a silicate, a hydroxide, a phosphate, a carbonate, an amine, and mixtures thereof. 30. The composition of claim 29 wherein said adherent alkaline foam alkalinity source is present in a concentration ranging from about 0.1 wt-% to 12.0 wt-%. 31. The composition of claim 30 wherein said adherent foam alkalinity source has a pH of about 6.5 or greater. 32. The composition of claim 24 wherein said adherent foam vinyl polymer emulsion comprise one or more acrylic monomers . 33. The composition of claim 32 wherein said vinyl polymer emulsion comprises a polyacrylate- polymethacrylate copolymer emulsion. 34. The composition of claim 24 wherein said adherent foam vinyl polymer emulsion is present in a concentration ranging from about 0.15 wt-% to 10.0 wt-%. 35. The composition of claim 24 comprising a surfactant. 36. The composition of claim 35 wherein said surfactant is selected from the group an anionic surfactant, a cationic surfactant, an amphoteric surfactant, a nonionic surfactant, and mixtures thereof. 37. The composition of claim 35 wherein said surfactant is present in a concentration ranging from about 0.00005 wt-% to 1.0 wt-%. 38. The composition of claim 35 wherein said surfactant comprises a nonionic surfactant present in a concentration ranging from about 0.00005 wt-% to 1.0 wt- %. 39. A method of cleaning hard surfaces, said method comprising the step of applying a foaming alkaline cleaning composition comprising an alkaline cleaner and an adherent foam stabilizing composition, said adherent foam stabilizing composition comprising: (a) an amount of alkalinity source effective to raise the pH of said composition to about pH 6.5 or greater; (b) an amount of vinyl polymer emulsion effective in providing an adherent foam; and (c) a balance of water. 40. The method of claim 39 wherein said adherent foam alkalinity source comprise an alkali or alkaline earth hydroxide. 41. The method of claims 39 wherein said alkaline cleaning composition is selected from the group consisting of an alkaline cleaner, an alkaline halogenated cleaner, a solvated alkaline cleaner and mixtures thereof. 42. The method of claim 39 wherein said adherent foam comprises a polyacrylate-polymethacrylate vinyl polymer emulsion. 43. The method of claim 39 wherein said foaming alkaline cleaning composition comprises from about 0.15 wt-% to 10.0 wt-% adherent foam stabilizing composition. 44. The method of claim 39 additionally comprising the steps of: (a) formulating the foaming alkaline cleaning composition of claim 39; (b) applying said composition to a surface; and (c) removing said composition after an extended time period. 45. The cleaned surface resulting from the method of claim 39.

Inventors: BESSE MICHAEL, GUTZMANN TIMOTHY, KEPPERS ROGER, RUHR RICHARD, BESSE, MICHAEL, GUTZMANN, TIMOTHY, KEPPERS, ROGER, RUHR, RICHARD
Applicants: ECOLAB INC, ECOLAB INC.
Application year: 1994
Main classification: C11D3
IPC codes: C11D3, C11D7